As I attempted to tackle my first summer project, I ran into a problem. The bolts/gasket/clamps that connect the cat to the center muffler are badly rusted and have essentially fused the two together. I figured I could take a hack saw and saw off the bolts, but from the angle of working underneath the car, it only let me do one of the four. Next thing that popped into my head is to cut the pipes behind the trouble area. I marked this with a red line in the picture. I briefly used a hacksaw and it did leave a mark, but not cut through. I was afraid that I might not get it to cut through with a hack saw. Can someone tell me the best solution to the problem I am having? How thick is the pipe at the end of the catalalytical converter?

Attached Thumbnails

 

Snibble, try a Dremel tool with a cutting wheel to remove the other 3 bolts.

__________________
Fred Hoelzle

Hi Ferdman... i forgot to mention I did use a dremel tool later on... that too didn't have an angle to reach the other bolts. I am thinking of using the dremel to cut the pipes at the ends of the cat about an inch before where the bolts/gasket are fused(shown with a red line in the picture). However... I am not sure what piece do I need for the dremel. As in.. what cutting instrument? i rarely use the dremel... so info is greatly appreciated.

Snibble, what are you attemting to do? Replace the catalytic converterand/or muffler?

I use the thin wafer wheels approx. 1" in diameter to cut metal pipe. It's important to have access around the entire pipe though so that you can keep the cutting wheel straight in the slot. Otherwise the thin wheel will break off as they can't tolerate any twisting or lateral loading. Be sure to wear safety glasses.

I suspect that your inability to get this particular clamp apart prevents it, but it would probably be easier to drop the entire exhaust system and work on it out from under the car.

__________________
Fred Hoelzle

How about just turning it with a wrench until it breaks? They usually break fairly easy compared to a new bolt.

I used a wrench... but nearly had it go through my hand with the amount of force I put on

Essentially... what I am trying to do is, cut at the part where its marked with the red line. Then connect straight pipes from the point straight to the rear muffler.

I used a dremel on parts like this too, but not to cut the pipe.

I would cut the bolts through, not off, any angle will do, then use a scredriver and hammer to split the nut or bolt depending on what you are cutting and the rest comes apart.

Just a suggestion, but this is the best solution I came up for these type of problems.

xp

__________________
1985 190E 2.3L - a constant project.

Maybe try making it nice and glowie red with a torch. That usually takes the fight right out of 'em.